From Weld Quality to Body Manufacturing & Distortion Engineering, ESI SYSWELD offers a unique computer-aided assessment of material characteristics, residual stresses and distortions by taking into account all the multi-physics that is involved in Welding, Assembly and Heat Treatment manufacturing processes:

• for process feasibility and material characteristic control
• for process security and product performance improvement
• for car body manufacturing and distortion control

ESI SYSWELD 2022.0 includes:

Welding Simulation:

• Visual-Weld 18.0.2 and SYSWELD Solvers 2022.0
• CSM Welding Advisor 18.0.2 and CSM Solver for Welding 2022.0

Spot Weld Rupture Solution: Visual Spot Weld Rupture 18.0.2 and CSM Solver for Welding 2022.0

Heat Treatment Simulation: Visual-HT 18.0.2 and SYSWELD Solvers 2022.0

Assembly Simulation: Visual-Assembly 18.0.2 and Virtual Assembly Solver (CSM) 2022.0:

1. Body manufacturing for auto industry
2. Distortion engineering on large welded assembly

Highlights of ESI SYSWELD:

Visual Weld and HT:

Fast, intuitive and easy-to-use welding and heat treatment simulation tool which covers all activities of the welding & heat treatment engineer. Some key new functionalities are:

• 1D Connection management for chaining between Visual-Assembly and Visual-Weld
• Proper chaining between Visual-Assembly and Weld by accounting variable thicknesses and several Young’s modulus
• Component bending optimized mechanical Behavior (Element Type 2)
• Solver parameter for feasibility simulation

Welding with CSM Solver

80% of the Sysweld industrial usages have been migrated inside ESI CSM (Computational Structural Mechanics) solver to strongly improve the performance and usability by taking full benefit from CSM platform’s DMP power and capability. The Physical platform convergence becomes the major step to consolidate on Thermo- Mechanical solver technology platform. It offers inter- operability and combinatory capabilities to enable large Manufacturing solutions combinatory value offer (SMF, BMS, BMA, WELD, CAST, Composite) and performance solutions value offer (VPS).

Key functionalities of this new welding advisor:

• Implementation within CSM of welding heat functionality and metallurgical transformation
• Implementation within CSM of Standard SYSWELD mechanical laws that consider thermal history and the mechanical consequences of the phase transformations
• Performance improvement
• Mechanical Nitsche contact implementation
• New Visual-Weld UI Based on CSM

Spot Weld Rupture

A new easy to use workflow has been implemented to allow the user to define a spot weld rupture process chain.

It provides a streamlined and intuitive workflow to evaluate spot weld process and strength virtually enabling individual engineers as well as cross disciplinary teams to explore, validate and resolve real world manufacturing and crash CAE process issues in terms of weld process window, quality, and strength.

Key functionalities of this new solution:

• Spot welding simulation
• Crash performance analysis (rupture) based on spot welding results
• Spot weld lobe prediction

Visual Assembly:

New generation, easy-to-use assembly simulation to ensure dimension accuracy “distortion control” of assemblies which:

• Covers complete car body manufacturing chain starting from the stamped part to pre-positioning to holding/clamping and finally welding/joining.
• Covers large welded assemblies with thick plates and multi-pass welds, which are common in the shipbuilding industry.

Some key new functionalities are:

• Spot welding remeshing improvement
• Scan to Mesh feature enhancement based on one single target
• CATGEN export for multiple State
• Highlighting of the Selected Entity Column and Row in the Sequence Manager
• Joints Manager
• Computation Monitoring
• Cumulative displacement contour support in WELD Multistage in Viewer

Please refer to the SYSWELD 2022.0 Release Notes for more information and to the Installation Guide for the installation of ESI SYSWELD 2022.0